Projector light source and system, including configuration for display of 3d images

ABSTRACT

An illuminator for an imaging system using a spatial light modulator has first color laser light directed by a dichroic element to a rotating member. The rotating member includes phosphor segments that respond to illumination by the first color light to emit second and third color light along a first path to the dichroic element for output, and a light transmitting segment that passes the first color through the rotating member along a second path to the dichroic element for output. In a 3D imaging mode, the first color laser light includes light of two wavelengths, and the phosphor segments include segments that emit second and third color light each of two wavelengths. The output light is directed to a second rotating member which has segments that selectively transmit one wavelength of each color, blocking the other wavelength. The second rotating members can optionally be operated to pass wavelengths of each color to form right and left images that can be viewed using corresponding passive right and left image filtering eyewear.

This application claims the benefit of Provisional Application No. 61/546,915, filed Oct. 13, 2011, the entirety of which is hereby incorporated by reference.

BACKGROUND

This relates to image projection systems and light sources usable with image projection systems.

There is a commercial need to provide a solid-state long lifetime light source that can create and illuminate a spatial light modulator (SLM) with enough lumens to be useful for mainstream data projectors.

There is a commercial need to provide projector systems using such a light source.

SUMMARY

Disclosed is a projector light source and projector system utilizing a hybrid laser and fluorescent emission light source. Also disclosed is an implementation of the light source and system for display of three-dimensional images.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example implementation of a laser pumped phosphor illuminator.

FIG. 2 illustrates the collector optics of the illuminator of FIG. 1.

FIG. 3 illustrates the blue relay path.

FIGS. 4-6 illustrate an example wheel segmentation and related characteristics for the R, G, Y and B segments of the color wheel.

FIGS. 7-8 give arrangement and characteristics of the dichroic mirror.

FIG. 9 illustrates the illuminator of FIG. 1, augmented for 3D imaging.

FIGS. 10 and 11 show examples of the phosphor and filter wheels for the system of FIG. 9.

FIGS. 12-20 give example parameters for the phosphors and filters used in the first and second wheels and corresponding left and right lenses of the glasses.

FIGS. 21-21 illustrate example color performances.

FIG. 23 illustrates example characteristics of the filters for the right and left eye filters of the filter wheel.

FIG. 24 illustrates example characteristics for the filters for the right and left eye lenses of the passive glasses. The glasses have the same filter cutoffs as the filters of the filter wheel, with the addition of a filter band to separate the two laser bands, 445 nm and 460 nm.

FIG. 25 illustrates the spectral energy from the phosphor wheel and the filter wheel filters overlaid.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

FIG. 1 illustrates an example implementation of a laser pumped phosphor illuminator. The illuminator includes laser banks 1 and 2, each with 16 1.6W blue lasers, Silflex mirror reflective strips, beam steering mirrors, a blue reflect dichroic mirror, a color wheel, and lenses arranged as shown.

FIG. 2 illustrates the collector optics of the illuminator of FIG. 1. Collimated blue laser light is injected into the optics, reflected by one side of a blue dichroic mirror and focused by an asphere lens onto the color wheel which includes angularly spaced different wavelength red, green and yellow (R, G, Y) color emitting phosphor segments and light transmissive segments or openings. Light emissions from the R, G, Y color emitting phosphor segments are collected by a set of collection optics, passed through the blue dichroic mirror, and focused by another asphere lens onto a light tunnel. The phosphor segments may take the form of spots of phosphor powder applied to the wheel. The spots are kept small (˜2 mm) for optimal light collection into the tunnel.

Blue (B) laser light transmitted through the light transmissive segments or openings is passed though the color wheel and directed via beam steering mirrors and optics to the other side of the blue dichroic mirror, from which it is reflected for focusing using the same other asphere lens onto the light tunnel. (The blue dichroic mirror passes the wavelengths of the red, green and yellow phosphor emissions, but reflects the wavelength of the blue laser light.) In the described example, the blue light relay path uses the direct laser blue light (445 nm or 460 nm) as a blue source. Laser beams are scattered by a diffuse transmissive section of the phosphor wheel and routed around to reflect off the blue dichroic mirror. In the illustrated arrangement, the light path of the transmitted blue light recombines with (i.e., realigns with) the light path of the red, green and yellow light before the condenser lens. The relay optics takes the form of a 1:1 pupil relay and maintains magnification of the system. A static diffuser is an alternative to a wheel diffuser located at or near an intermediate image plane. The blue relay path is illustrated in FIG. 3. A weak optical diffuser may be included in the blue light relay path.

The output from the light tunnel is directed to illumination optics and onto an N×M array of individually addressable light pixel switches of a spatial light modulator, such as an N×M array of micromirrors of a digital micromirror device (DMD) (e.g., a DLP™ device from Texas Instruments). The color wheel rotates in synchronism with operation of the light pixel switches to project the red, green, yellow and blue light for integration into a composite color image on a display surface.

FIGS. 4-6 illustrate an example wheel segmentation and related characteristics for the R, G, Y and B segments of the color wheel. As shown in FIG. 4, a circumferential serial arrangement of segments may be a twice repeated same sequence of 55° Y, 57° G, 40° R and 28° B. An example wavelength spectrum selection for selection of phosphors is shown in FIG. 5 wherein G (tallest curve with leftmost peak) has a response of 0.045-0.05 a.u. at a wavelength of 480-530 nm, Y (next tallest curve with middle peak) has a response of 0.04-0.045 a.u. at a wavelength of 530-580 nm, and R (shortest curve with rightmost peak) has a response of about 0.015 a.u. at a wavelength of around 630 nm. FIG. 6 shows an example color gamut. Use of yellow as a fourth color enables a good balance between the large amount of blue available in the system, and helps provide a good white point. The time sequential nature of imaging using segments of a rotating color wheel allows for phosphor spectral overlap (i.e., can use yellow). The algorithm used for imaging may be the same as used in the BrilliantColor™system.

The dichroic mirror, shown schematically in FIG. 7 (blue shown going down and to the left; green on top, yellow in the middle, and red on the bottom shown going to the right in three places), is configured for reflecting the blue laser light, but for transmitting the green, yellow and red phosphor wavelengths. The design of the mirror is preferably chosen to give filter cutoffs, shown by the example curves in FIG. 8, which will maximize laser throughput assuming random polarization state of the laser and phosphor emissions. The illustrated design (see FIG. 8) has response characteristics chosen for use with 445 nm laser input light.

The illustrated light source arrangement may be implemented without additional electronics drivers or cooling elements needed for LED sources. Although other arrangements may be used, the illustrated example uses a single dichroic fold mirror for filtering phosphors, directing laser light to phosphors and recombining blue laser light with the phosphor emitted RGY light. The use of laser light and phosphor emissions as described enables the creation of a brighter light source (more lumens) in a small etendue than when LED sources are used. Brightness may be increased by increasing the amount of laser power that is incident on the phosphor surface before thermal quenching occurs. The color wheel (i.e., phosphor wheel) may be implemented using a reflective metal substrate surface to minimize thermal quenching by removing heat from the phosphor. The use of inherent laser polarization relaxes the requirements on the dichroic fold mirror.

The described architecture may be augmented to enable using a spatial light modulator such as a DLP™ digital micromirror device for the projection of images which are viewable in three dimensions (3D) using passive viewing glasses. Unlike 3D imaging approaches that require active glasses, passive viewing glasses do not require power to the eyewear, do not require synchronization of left and right eyewear shutters, and have a lower eyewear cost.

The described light source provides a projector utilizing multiple colors (RGBY), having filtering of phosphor pump light from the individual colors, and providing enough lumens in a small etendue which is suitable for use as a light source for small spatial light modulators.

An example augmented architecture of a laser pumped phosphor illuminator usable for 3D imaging is shown in FIG. 9. The general arrangement is similar to that previously described with reference to the arrangement shown in FIG. 1; however, the color wheel and laser light sources are modified to provide two wavelength selectable sources for each R, G, Y and B color and a way for time sequentially alternating between the two sets of colors.

Wavelength selection 3D creates the left and right eye images by providing two of each color displayed. The illustrated architecture utilizes a time sequential wavelength selection process in which two blues, two reds, and two greens are produced, one for each eye. The two blues are provided by utilizing blue light lasers of different wavelengths, one bank of lasers emitting light at 448 nm wavelength and one bank of lasers emitting light at 460 nm wavelength, to provide both the light sources for pumping the phosphor conversion wheel and the two blue colors. The banks are individually electronically controlled to produce the different blue colors, with either or both laser wavelengths usable to illuminate and excite the phosphors.

As shown in FIG. 9, a second wheel may be placed in the optical path just before the integrator rod (light tunnel, above). The wheel includes filters for time sequentially blocking or transmitting a selected one of each of the two wavelengths for each color.

The second color wheel may be arranged for relative movement into or out of the projection optical path, for switching between 3D image and 2D image projection modes.

The first and second color wheels for the system of FIG. 9 are shown in FIGS. 10 and 11.

The first wheel (the phosphor conversion wheel) shown in FIG. 10 may have a segmentation arrangement similar to that described previously for the wheel shown and described with reference to FIGS. 4-6. The phosphors and sequences may be as previously described.

The second wheel (wavelength filter wheel) has two sections as shown in FIG. 11: a left eye wavelength filter and a right eye wavelength filter. The second wheel is synchronized with the first wheel, so that B, Y, G and R light of a first wavelength (or first set of wavelengths) for each color is passed by the filter in synchronism with the modulation of the spatial light modulator pixel switches for the left eye image and B, Y, G and R light of a second wavelength (or second set of wavelengths) for each color is passed in synchronism with the modulation of the spatial light modulator pixel switches for the right eye image. (The glasses have left and right lenses with corresponding left and right image wavelength filtering.) The output may, for example, be a 120 Hz left/right cadence of 3D image frames.

The phosphors provide a large wavelength response which is useful in the wavelength selection process. The blue wavelengths may be coordinated so that only one wavelength laser emits light at a time (synchronized with the left/right filtering), or both wavelengths may be emitted with the second (filter) wheel serving to pass only the blue wavelength corresponding to the currently images left or right eye modulation.

FIGS. 12-20 give example parameters for the phosphors and filters used in the first and second wheels and corresponding left and right lenses of the glasses.

FIG. 12 shows the spectral energy of the phosphors and lasers with the filters overlaid.

FIGS. 13 and 14 show the two reds created by the filter wheel. FIGS. 15 and 16 show the two greens created by the filter wheel. FIGS. 17 and 18 show the two yellows created by the filter wheel. The BrilliantColor™ algorithms recapture the yellows and spokes. FIGS. 19 and 20 show the two blues created by electronically selecting between the 448 nm and 460 nm lasers. In this implementation, when the blue color imaging for left or right eye occurs only the bank of lasers corresponding to one wavelength is illuminated (although both banks can be illuminated for the pumping of the other color generating phosphors), and only the filters in the glasses discriminate between the two blues. (In other implementations, both laser wavelengths can be turned on when either blue is being images, with the filter wheel used for the discrimination of which wavelength is used for illuminating the display surface.)

FIGS. 21-22 illustrate example color performances.

FIG. 23 illustrates example characteristics of the filters for the right and left eye filters of the filter wheel.

FIG. 24 illustrates example characteristics for the filters for the right and left eye lenses of the passive glasses. The glasses have the same filter cutoffs as the filters of the filter wheel, with the addition of a filter band to separate the two laser bands, 445 nm and 460 nm.

FIG. 25 illustrates the spectral energy from the phosphor wheel and the filter wheel filters overlaid.

The DDP4421 has dual PCC color correction registers that enable individual left/right eye color correction. This allows for white point and individual color matching for the individual left and right eyes. Brightness matching can be accomplished either using laser current or PCC color control

With the advancement of phosphor technology, such as advancements in quantum dot phosphors, instead of using a filter wheel and repeating the sequence of phosphors for yellow, red and green, the filter wheel may be omitted with phosphors of different yellow, red and green light emission characteristics used for the repetition of the colors.

Those skilled in the art to which the invention relates will appreciate that other modifications may be made to the described embodiments, and yet further embodiments realized, within the scope of the invention to be claimed. 

1. An illuminator for an image projection system, comprising: a source of laser light of a first wavelength; a rotable member including first and second phosphor segments and a segment transmitting light of the first wavelength, the respective segments angularly spaced about the rotatable member; a dichroic optical element; light output optics; and light directing optics; the first and second phosphor segments configured to emit light of second and third wavelengths when illuminated by light of the first wavelength; the light directing optics configured to direct light of the first wavelength transmitted through the rotatable member to the dichroic optical element; and the dichroic optical element configured to pass the first wavelength light received from the laser light source onto the rotatable member for sequential illumination of the respective phosphor and light transmitting segments as the rotatable member rotates, to pass light of the second and third wavelengths emitted from the first and second phosphor segments from the rotatable member to the light output optics, and to pass light of the first wavelength directed by the light directing optics from the light transmitting segment to the light output optics.
 2. The illuminator of claim 1, wherein the first wavelength is a blue color wavelength, the second wavelength is a green color wavelength, and the third wavelength is a red color wavelength.
 3. The illuminator of claim 2, wherein the rotatable member includes a third phosphor segment angularly spaced relative to the first phosphor segment, the second phosphor segment, and the light transmitting segment; the third phosphor segment is configured to emit light of a fourth wavelength which is a multiprimary color wavelength when illuminated by light of the blue color wavelength; and the dichroic optical element is configured to pass light of the fourth wavelength emitted from the third phosphor segment from the rotatable member to the light output optics.
 4. The illuminator of claim 3, wherein the fourth wavelength is a yellow color wavelength.
 5. The illuminator of claim 4, wherein the dichroic optical element is a dichroic mirror configured to reflect light of the first wavelength and to transmit light of the second, third and fourth wavelengths.
 6. The illuminator of claim 5, wherein the light transmitting segment is a diffuse transmissive section of the rotatable member.
 7. The illuminator of claim 6, wherein the phosphor segments comprise phosphor powders adhered to a reflective metal substrate surface.
 8. The illuminator of claim 7, wherein the light directing optics functions to direct light reflected from a first side of the dichroic mirror through the diffuse transmissive section for reflection by an opposite second side of the dichroic mirror to the light output optics.
 9. The illuminator of claim 8, wherein the light output optics comprises a light tunnel.
 10. The illuminator of claim 9, wherein the light output optics further comprises an ashpere lens for focusing light from the dichroic mirror onto the light tunnel.
 11. The illuminator of claim 10, further comprising light collection optics positioned between the dichroic mirror and the rotatable member for collecting light emitted by the phosphor segments for passing to the dichroic mirror.
 12. The illuminator of claim 11, wherein the segments are configured in a circumferential repeated serial arrangement of segments.
 13. The illuminator of claim 12, wherein the segments have different sizes.
 14. The illuminator of claim 13, wherein the green and yellow color wavelength emitting phosphor segments are larger than the red color wavelength emitting phosphor and blue color wavelength light transmissive segments of the rotatable member.
 15. The illuminator of claim 14, wherein: the illuminator further comprises a source of laser light of a blue color fifth wavelength; the segment transmitting light is one or more segments for transmitting light of each of the blue color first and fifth wavelengths, and further includes fourth, fifth and sixth phosphor segments configured to emit light of respective green color sixth, red color seventh and yellow color eighth wavelengths when illuminated by light of at least one of the blue color first and fifth wavelengths; the light directing optics includes optics configured to direct light of the blue color fifth wavelength transmitted through the rotatable member to the second surface of the dichroic optical element; and the dichroic optical element is configured to pass the at least one of the blue color first and fifth wavelength light received its source onto the rotatable member for sequential illumination of the respective phosphor and light transmitting segments as the rotatable member rotates, to pass light of the green color second and sixth, red color third and seventh, and yellow color fourth and eighth wavelengths emitted from the respective phosphor segments from the rotatable member to the light output optics, and to pass light of the first and fifth wavelengths directed by the light directing optics from the one or more light transmitting segments to the light output optics.
 16. The illuminator of claim 15, wherein the rotatable member is a first rotatable member; and the illuminator further comprises a second rotatable member including a first one or more light selection segments configured for passing light of the first, second, third and fourth wavelengths while blocking light of the fifth, sixth, seventh and eighth wavelengths; and a second one or more light selection segments configured for blocking light of the first, second, third and fourth wavelengths while passing light of the fifth, sixth, seventh and eighth wavelengths; the first one or more light selection segments being angularly spaced from the second one or more light selection segment.
 17. The illuminator of claim 16, wherein the second rotatable member is configured for selective switching between a first operational mode in which light of the first, second, third, fourth, fifth, sixth, seventh and eighth wavelengths directed from the dichroic mirror to the light output optics is passed sequentially through the first one or more light selection segments and the second one or more light selection segments, and a second operational mode in which light of the first, second, third, fourth, fifth, sixth, seventh and eighth wavelengths is transmitted from the dichroic mirror to the light output optics without going through the first or second one or more light selection segments.
 18. The illuminator of claim 17, wherein the second rotatable member is configured for movement into and out of a position between the dichroic optical element and at least a portion of the light tunnel.
 19. The illuminator of claim 4, wherein: the illuminator further comprises a source of laser light of a fourth wavelength; the segment transmitting light is one or more segments for transmitting light of each of the first and fourth wavelengths, and further includes third and fourth phosphor segments configured to emit light of respective fifth and sixth wavelengths when illuminated by light of at least one of the first and fourth wavelengths; the light directing optics includes optics configured to direct light of the fourth wavelength transmitted through the rotatable member to the dichroic optical element; and the dichroic optical element is configured to pass the at least one of the first and fourth wavelength light received its source onto the first rotatable member for sequential illumination of the respective phosphor and light transmitting segments as the rotatable member rotates, to pass light of the second, third, fifth and sixth wavelengths emitted from the respective phosphor segments from the rotatable member to the light output optics, and to pass light of the first and fourth wavelengths directed by the light directing optics from the one or more light transmitting segments to the light output optics.
 20. The illuminator of claim 19, wherein the rotating member is a first rotating member; and further comprising a second rotatable member including a first one or more light selection segments configured for passing light of the first, second and third wavelengths while blocking light of the fourth, fifth and sixth wavelengths; and a second one or more light selection segments, angularly spaced from the first one or more light selection segments, configured for passing light of the fourth, fifth and sixth wavelengths while blocking light of the first, second and third wavelengths. 